TOYOTA RAV4 1996 Service Repair Manual

MX02C−02
Q06216
4th Driven Gear3rd Driven GearNeedle Roller Bearing
1st Gear Bearing Inner Race Spacer
Inner Race
2nd Gear
Spacer
Output Shaft Rear Bearing
SpringNo.1 Hub Sleeve
Needle Roller Bearing
1st Gear
Synchronizer Ring
Ball
Output Shaft Front
Bearing
Output Shaft Shifting Key
No.1 Clutch Hub
Synchronizer Ring
 Non−reusable part MX−36
− MANUAL TRANSAXLEOUTPUT SHAFT
1996 RAV4 (RM447U)
OUTPUT SHAFT
COMPONENTS

MX02D−03
Q06370
1st Gear
2nd Gear
Z00218
Z00219
Z00220
− MANUAL TRANSAXLEOUTPUT SHAFT
MX−37
1996 RAV4 (RM447U)
DISASSEMBLY
1. MEASURE 1ST AND 2ND GEARS THRUST CLEAR-
ANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1st gear: 0.10 − 0.35 mm (0.0039 − 0.0138 in.)
2nd gear: 0.10 − 0.45 mm (0.0039 − 0.0177 in.)
Maximum clearance:
1st gear: 0.40 mm (0.0157 in.)
2nd gear: 0.50 mm (0.0197 in.)
2. CHECK 1ST AND 2ND GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between
the gear and shaft.
Standard clearance:
1st gear: 0.009 − 0.051 mm (0.0004 − 0.0020 in.)
2nd gear: 0.009 − 0.053 mm (0.0004 − 0.0021 in.)
Maximum clearance:
1st and 2nd gears: 0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear,
needle roller bearing or shaft.
3. REMOVE OUTPUT SHAFT REAR BEARING, 4TH
DRIVEN GEAR AND SPACER
(a) Using a press, remove the bearing and 4th driven gear.
(b) Remove the spacer.
4. REMOVE 3RD DRIVEN GEAR AND 2ND GEAR
Using a press, remove the 3rd driven gear and 2nd gear.
5. REMOVE NEEDLE ROLLER BEARING, SPACER AND
SYNCHRONIZER RING
6. REMOVE INNER RACE AND BALL FROM OUTPUT
SHAFT

Z00222
Q06202
SST
Q00296
SST MX−38
− MANUAL TRANSAXLEOUTPUT SHAFT
1996 RAV4 (RM447U)
7. REMOVE NO.1 HUB SLEEVE ASSEMBLY AND 1ST
GEAR
Using a press, remove the No.1 hub sleeve and 1st gear.
8. REMOVE SYNCHRONIZER RING AND NEEDLE
ROLLER BEARING
9. REMOVE 1ST GEAR BEARING INNER RACE
Using SST and a press, remove the 1st gear bearing inner race.
SST 09950−00020
10. REMOVE OUTPUT SHAFT FRONT BEARING
Using SST, remove the output shaft front bearing.
SST 09950−00020, 09950−00030

WM0064
MX02E−02
WM0065
MT0780
MT0787
− MANUAL TRANSAXLEOUTPUT SHAFT
MX−39
1996 RAV4 (RM447U)
INSPECTION
1. INSPECT 1ST GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring. Turn the
synchronizer ring in one direction while pushing it to the
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring and gear
cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(c) Check again the braking effect of the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring, and apply a small amount of the fine lapping com-
pound on gear cone.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
2. INSPECT 2ND GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Check the braking effect of the synchronizer ring.
(c) Turn the synchronizer ring in one direction while pushing
it to the gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.
(d) Using a feeler gauge, measure the clearance between
the synchronizer ring back and gear spline end.
Minimum clearance: 0.7 mm (0.028 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring.

WM0066
Q06203
AB
A
Q06191
MX−40
− MANUAL TRANSAXLEOUTPUT SHAFT
1996 RAV4 (RM447U)
3. MEASURE NO.1 SHIFT FORK AND HUB SLEEVE
CLEARANCE
Using a feeler gauge, measure the clearance between the hub
sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork or
hub sleeve.
4. INSPECT OUTPUT SHAFT
(a) Check the output shaft for wear or damage.
(b) Using a micrometer, measure the outer diameter of the
output shaft journal surface.
Minimum outer diameter:
Part A: 37.526 mm (1.4774 in.)
Part B: 34.512 mm (1.3588 in.)
(c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 in.)

MX02F−04
Q06204
Front
Q06205
SST Align the holes
Z00225
Q06206
SST
− MANUAL TRANSAXLEOUTPUT SHAFT
MX−41
1996 RAV4 (RM447U)
REASSEMBLY
HINT:
Coat all of the sliding and rotating surfaces with gear oil before
reassembly.
1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
(a) Install the 3 springs and shifting keys to the clutch hub.
(b) Install the hub sleeve to the clutch hub.
HINT:
Direct identification groove of the hub sleeve to the front of the
transmission.
2. INSTALL 1ST GEAR BEARING INNER RACE
Using SST and a press, install the 1st gear bearing inner race.
SST 09506−35010
HINT:
Align the hole of the output shaft and inner race.
3. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR,
SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO
OUTPUT SHAFT
(a) Apply MP grease to the needle roller bearing.
(b) Install the 1st gear.
(c) Place the synchronizer ring (for the 1st gear) on the gear
and align the ring slots with the shifting keys.
(d) Using SST and a press, install the 1st gear and No.1 hub
sleeve.
SST 09316−60011 (09316−00041)
4. MEASURE 1ST GEAR THRUST CLEARANCE
(See page MX−37)

Q06314
MT0792
N00495
Z00390
Z00391
SST MX−42
− MANUAL TRANSAXLEOUTPUT SHAFT
1996 RAV4 (RM447U)
5. INSTALL BALL AND INNER RACE TO OUTPUT SHAFT
HINT:
Align the groove of the inner race and ball.
6. INSTALL SPACER, NEEDLE ROLLER BEARING, SYN-
CHRONIZER RING, 2ND GEAR AND 3RD DRIVEN
GEAR
(a) Install the spacer.
(b) Apply MP grease to the needle roller bearing.
(c) Place the synchronizer rings (for the 2nd gear) on the
gear.
NOTICE:
Do not install the synchronizer ring for the 1st gear.
(d) Install the 2nd gear.
(e) Using a press, install the 3rd driven gear.
NOTICE:
Align the clutch hub grooves with the projections on the
synchronizer ring.
7. MEASURE 2ND GEAR THRUST CLEARANCE
(See page MX−37)
8. INSTALL SPACER AND 4TH DRIVEN GEAR
(a) Install the spacer.
(b) Using a press, install the 4th driven gear.
9. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the bearing.
SST 09506−30012

Z00392SST
− MANUAL TRANSAXLEOUTPUT SHAFT
MX−43
1996 RAV4 (RM447U)
10. INSTALL OUTPUT SHAFT FRONT BEARING
Using SST and a press, install a new output shaft front bearing.
SST 09316−60011 (09316−00071)

MX02G−02
Z17558
GasketO−Ring
Oil Strainer
Oil Pump Driven Rotor
Oil Pump Drive Gear Oil Pump Drive Rotor
Oil Pump Cover Spring Holder Spring Ball Relief Valve Transmission Oil Pump
Case
N·m (kgf·cm, ft·lbf): Specified torque
 Non−reusable part
10 (105, 8)
10 (105, 8)

 MX−44
− MANUAL TRANSAXLEOIL PUMP (2WD)
1996 RAV4 (RM447U)
OIL PUMP (2WD)
COMPONENTS

MX02H−01
Z00242
Z00243
Z00244
− MANUAL TRANSAXLEOIL PUMP (2WD)
MX−45
1996 RAV4 (RM447U)
INSPECTION
1. CHECK ROTOR BODY CLEARANCE
(a) Install the oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measure the body clearance be-
tween the drive rotor and oil pump case.
Standard clearance:
0.10 − 0.16 mm (0.0039 − 0.0063 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
2. CHECK ROTOR TIP CLEARANCE
(a) Install the oil pump drive gear to the drive rotor.
(b) Using a feeler gauge, measure the tip clearance between
the drive and driven rotors.
Standard clearance:
0.08 − 0.15 mm (0.0031 − 0.0059 in.)
Maximum clearance:
0.30 mm (0.0118 in.)
3. CHECK SIDE CLEARANCE
Using a precision straight edge and feeler gauge, measure the
side clearance of both rotors.
Standard clearance:
0.03 − 0.08 mm (0.0012 − 0.0031 in.)
Maximum clearance:
0.15 mm (0.0059 in.)